DK2994283T3 - PLATE OF DRY PILLOW AND PROCEDURE FOR ITS PREPARATION - Google Patents

Description

Description of the Invention The present invention relates to a dry mortar plate for producing a fresh mortar for covering thin-layer plaster of structural walls such as, for example, hollow brick flooring, and to a method for making such a dry mortar plate.

Dry mortars are prefabricated dry mixtures (so-called industrial mortars), consisting of mineral binders (cement, lime or gypsum), stone particles, additives and additives which are to be mixed with water only on site and are therefore ready for use.

DE 25 11 097 A1 discloses a water activatable band or a water activatable strip. These comprise a fiber material or a foamed plastic material impregnated with a water-reactive, cementitious substance which reacts with water to form a cured mass. According to DE 25 11 097 A1, the cementitious material is solidified by a binder which is, for example, a natural or synthetic rubber. It may also contain a thickening agent as an additional binder, for example cellulose ether. As part of an embodiment, DE 25 11 097 A1 discloses that 27% by weight of glass microspheres from the company Fillite Ltd. can be used in combination with styrene / butadiene rubber as an organic binder.

DE 1 954 160 A1 describes a mortar plate with a dry mortar mixture of cement, lime and mortar sand. The dry mortar mixture can be solidified by a water-soluble plastic. After placing on a number of stones, the dry mortar is brought into hydraulic bonding with the addition of water.

[0005] The article "Mortel Band - Revolution am Bau", rent-a-scientist, March 18, 2010 by Alexander Herrmann assumes a strip of mortar or a mortar roll comprising a support layer and then applied dry cement, and an adhesive.

EP 0 005 814 A1 discloses a mortar band containing an aggregate of irregular tile, spunbonded fabric or needle felt and a hydrophilic polymer as an adhesive which is pressed with the dry mortar in the form of a band.

EP 2 336 096 A1 discloses pressed mortar molds which are in the form of briquettes or granules, in which CSH granules, perlite, vermiculite, pumice and expanded clay can be used as pressing aids. The bodies of dry mortar always have an explosive which serves to open the dry mortar bodies by contact with water. The pressed dry mortar bodies are added as a filling in a container to which the corresponding amount of water is added. The dry mortar bodies break when water is added.

From DE 10 2004 033 945 A1 there is a generic dry mortar band for bonding bricks, bricks or the like. The mortar band comprises a support strip and a dry cement mortar mixture and a binder, wherein the binder is a water-soluble matrix having a melting point above 40 ° C selected from the group of organic polymers, hydrated salts, carboxylic acids and salts thereof, hydrophobic compounds in connection with hydrophilizing agents. substances as well as sugar or urea. This is then connected to the mixture applied to the support strip by heat treatment and solidified by subsequent cooling. The mixture can also be arranged on both sides of the carrier strip. According to a preferred embodiment, it is divided into segments of approximately the same length on transverse notches at transverse notches or spaces. Excess water can run off the notches during irrigation. The preparation of mortar strips is carried out by applying a dry mixture of cement mortar and a binder to a support strip, heat treatment and subsequent cooling. According to DE 10 2004 033 945 A1, the mortar band can also be in the form of longitudinal stiff plates.

The known mortar belt has proved its value. However, it was established within the scope of the invention that the cohesiveness of the mortar band is not always good enough. The mortar band, despite the inside strip, tends to partially break up. In addition, the mortar band tends to crumble at the edge. The wear resistance is also not good enough.

It is therefore the object of the present invention to provide a dry mortar plate having at least one solidified layer of dry mortar with a water-soluble adhesive which dry mortar plate should exhibit a better cohesive force and improved strength. It must also be ensured that all components of the binder mixture are wetted sufficiently and uniformly by irrigation.

It is a further object to provide a method for making the dry mortar plate.

These objects are achieved by a dry mortar plate according to claim 1 and a method according to claim 10. Advantageous further developments of the invention are characterized in the subsequent subclaims.

The invention will be exemplified in the following with reference to a drawing. Showing:

Figure 1: A schematic longitudinal section through a dry mortar plate according to the invention in a first embodiment

Figure 2: A schematic plan view of the dry mortar plate of FIG. 1

Figure 3: A clean schematic illustration of a device according to the invention

Figure 4: A schematic longitudinal section through a tile row with a series of dry mortar plates according to the invention

Figure 5: A schematic longitudinal section through two superimposed rows of bricks in a brick with an intermediate layer of fresh mortar according to a first embodiment

Figure 6: A schematic longitudinal section through two superimposed rows of bricks in a masonry with an inserted fresh mortar layer according to another embodiment

Figure 7: A schematic longitudinal section through a dry mortar plate according to the invention according to yet another embodiment.

According to a first embodiment of the invention, a particularly box-shaped dry mortar plate 1 comprises a support strip 2, on which at least one side, preferably on both sides (Fig. 1.2.), Is placed on a dry mortar layer 3.4, which is solidified by means of a water-soluble adhesive. The dry mortar plate 1 has a plate length direction 1a, a perpendicular plate transverse direction 1b and a height direction 1c or thickness direction perpendicular to both the plate length direction 1a and the transverse direction 1b of the plate.

In a particularly rectangular carrier strip 2, it is a sheet of textile in particular. Preferably, the carrier strip 2 is woven and / or knitted and / or nonwoven and / or knitted fabric. The carrier strip 2 is preferably made of cotton fibers and / or polyester fibers and / or glass fibers and / or carbon fibers and / or basalt fibers. In particular, it is a single-layered fabric (2D woven fabric) or a multilayered fabric, whose individual fabric layers are sewn together but separated from each other (the 3D fabric stood). In addition, the carrier strip 2 has a first carrier strip surface 5 and one opposite this second carrier strip surface 6. The two carrier strip surfaces 5,6 are opposite to each other in the plate thickness direction 1c. In this case, the carrier strip 2 has seen, along its entire surface area, openings or holes 7 passing through from the first to the second carrier strip top 5.6. In the case of tissue, these are holes 7, for example, about the gaps between the warp and weft threads. The holes 7 preferably have a cross section of 2 mm x 2 mm to 50 mm x 50 mm, preferably 4 mm x 4 mm to 10 mm x 10 mm. At high mesh size, the hard-mortar mixtures are preferably a reinforcement in the form of individual fibers.

As already explained, at least one dry mortar layer 3 is provided on both the first support strip top 5 and on the second support strip top 6 in each case. The carrier strip 2 is covered on at least one side, preferably on both sides, by at least one dry mortar layer 3. 4th The carrier strip 2 is thus arranged between the two layers of dry mortar 3,4. Both dry mortar layers 3,4 are opposite to each other in the plate thickness direction 1c. In this way, the holes 7 in the carrier strip 2 preferably penetrate both dry mortar layers 3,4, and are thereby connected to each other and to the carrier strip 2.

The especially box-shaped dry mortar layers 3,4 each have an outer layer surface 8 facing away from the carrier strip 2, as well as two opposing and mutually parallel layer side edges 9 and two opposing layer edges 10 perpendicular to the layer side edges 9. Layer side edges 9 and layer edges 10 of the first and second dry mortar layers 3,4, thereby in each case preferably terminating in pairs with each other, forming the plate side edges 11 and plate end edges 12 of the dry mortar plate 1, and both of the layer tops 8 each form a plate surface 13a, b of the dry mortar plate 1. Furthermore, the layer side edges 9 extend the plate side edges 11 extend parallel to the plate length direction 1a and the laying edges 10 and the plate end edges 12 extend parallel to the plate cross direction 1b.

The dry mortar layers 3,4 each consist of a dry mortar mixture which is solidified by a water-soluble, meltable adhesive. The dry mortar mixture consists in a known manner of a mineral, especially hydraulic, binder, preferably cement, especially Portland cement, and / or lime, and aggregates and optionally additives, for example, stone flour and / or fly ash and / or fibers and / or additives. In particular, the dry mortar mixture has as additives, a polysaccharide thickener and a mineral thickening agent according to DE 199 16 117 A1 to obtain a sheet-like consistency of the fresh mortar after manufacture.

[0019] As already explained, the adhesive is a water-soluble, hardened melt adhesive. The adhesive forms a solid adhesive matrix connecting the individual components of the dry mortar mixture to each other and to the carrier strip 2. The compound is made by melting and subsequently cooling the adhesive, which will be discussed in more detail below. As a result, the adhesive is melted or baked with the components of the dry mortar mixture and carrier strip 2. Preferably, the adhesive has as its main component a water-soluble component selected from the group of organic polymers, hydrated salts, carboxylic acids and salts thereof, hydrophobic agents in combination with hydrophilizing agents, or sugars. urea, whereby this water-soluble component has a melting point between 30 ° C and 160 ° C. With regard to the other possible compositions of the adhesive, reference is made to DE 10 2004 033 945 B4.

[0020] Within the invention, it has now surprisingly been found that the strength and cohesiveness of the dry mortar layers 3,4 at a high proportion of the light aggregate (light rock particles) with open pores and with closed pores can be substantially improved. A lightweight aggregate (light stone particles) means a grainy material for use in construction. Stone particles are subdivided according to their origin, structure, particle size as well as particle density and can be natural, industrially manufactured or recycled. Basically, based on particle density pRg, determined according to DIN 4226, a distinction is made between light aggregate (light rock particles) (pR9 <2000 kg / m3) normal aggregate (normal rock particles) (pRg = 2000-3000 kg / m3) and heavy aggregate (pRg = 2000-3000 kg / m3). heavy rock particles) (pRg> 3000 kg / m3). According to the invention, the dry mortar layers 3.4 contain a total of 5 to 35% by weight, preferably 10 to 25% by weight, of light aggregate with open and closed pores based on dry weight of the dry mortar layers 3.4. The lightweight aggregate consists in known manner of single, unbroken and / or broken, lightweight aggregate particles 14, each equipped with open pores or closed pores, and consisting of natural and / or artificially produced mineral substances.

[0021] A distinction is made between light stone particles with closed pores (light aggregates with closed pores) such as expanded clay and expanded glass with light aggregate particles with closed pores and light stone particles with open pores (light aggregates with open pores) such as pumice, vermiculite and expanded perlite with light aggregate particles with open pores as follows: the light aggregate particles with closed pores produced by an expansion or sintering process, respectively, have a strongly cross-linked pore system and a relatively dense sintered skin. The sintered skin has capillary highly active sintering pores with a diameter of approx. 0.01 to 40 micrometers. Also, light aggregate particles with closed pores are not completely closed on the grainy surface. Light aggregate particles with closed pores suck very quickly in the beginning. Then, water absorption decreases sharply over time. Light aggregate particles with open pores, on the other hand, have an evenly distributed, high porosity over the total particle cross-section. They have a very high capillary absorbency and are saturated with water within seconds to minutes.

Due to their porosity, mainly lightweight open pore aggregate particles 14 have very low particle pressure resistance. Preferably, their particle pressure resistance is at 0.01 N / mm 2 to 2 N / mm 2, preferably from 0.01 N / mm 2 to 1 N / mm 2. Particle pressure resistance depends in particular on the lightweight aggregate used. Nevertheless, the dry mortar plate 1 according to the invention has surprisingly good strength properties and a high abrasion resistance. It is believed that the molten adhesive penetrates the open pores of the light aggregate particles 14 and is mechanically clamped therein upon cooling. Thereby, the cohesiveness of the individual constituents of the dry mortar mixture is greatly improved, which leads to the good strength properties of the dry mortar plate according to the invention. The particle pressure resistance of light aggregates with closed pores is preferably from 2 to 7 N / mm 2.

A further advantage of the large proportion of light aggregate with open and closed pores is the fact that an open porosity is generated in the total dry mortar layer 3.4. By the fact that the individual components of the dry-butter mixture are attached to each other by the adhesive, the light aggregate particles14 produce a defined, stable pore volume with interconnected pores. This ensures that mold water can flow throughout the mortar plate 1 and that uniform wetting of binder particles is achieved. Thus, the dry mortar plate 1 has a high absorbency. Thus, good and uniform strength properties of the cured mortar layer of the manufactured mortar plate 1 are ensured.

In addition, a significantly faster reworking of the irrigated mortar board (laying on the next layer of bricks) is possible.

Absorbability of the dry mortar plate 1 was determined as follows: A dry mortar plate 1 is weighed and positioned with a plate surface 13b on a smooth, impervious surface (e.g. glass pane). The water is applied with a pump spray bottle with atomizer. The weight of the water in the bottle is recorded and weighed negatively after watering. In addition, loss of water must be collected, which water may spread over the edges of the plate by spraying and counterbalanced.

The dry mortar plate 1 is cyclically watered from above with the pump spray bottle. For this, the dry mortar plate 1 is sprayed with a spray of approx. 1 mg. Each irrigation interval is then completed when the amount of water has been completely absorbed by the dry mortar plate 1. This is repeated so long until a fine film of water on the surface is clearly visible (surface shining) that no water absorption takes place. Finally, check that the fine film of water stays at least 120 s on the upper plate surface 13a, without being absorbed by the dry mortar plate 1. If necessary, re-irrigate and repeat the check. In addition, a visual inspection of the underside for irrigation of the dry mortar plate is advisable to assess the plate quality. If the control lasts longer than 300 s, the test results must be discarded and the test repeated with a new sample. Then the weight of water consumed was determined and compared to the plate weight. The absorbency [weight%] of the dry mortar plate 1 was determined from the absorption of water based on the total dry weight of the dry mortar plate 1. The absorbency is preferably between 20 and 80% by weight, preferably between 40 and 70% by weight.

The absorbency of the mortar plate 1 is adjusted according to the invention by the type of open pores and closed pores of the light aggregate and the content of the light aggregate with open and closed pores, depending on the binder and exposure level (the required water-cement ratio). Preferably, the light aggregate having open and closed pores is perlite or vermiculite or expanded glass or hydrosilicates (foamed water glass) or expanded clay or porous sand, aerogels, expanded slate, pumice, tufts or mixtures of the aforementioned light aggregates. Particularly advantageous is a mixture of expanded glass, vermiculite and perlite. Further, the dry mortar layers 3,4 may be of light aggregates with hollow glass balls, glass flakes and / or polystyrene.

In particular, the porosity of the light aggregate particles14 plays a role in adjusting the absorbency of the mortar plate 1. This is for expanded glass at 88-92 vol.% For perlite at ca. 95 vol.% And for vermiculite of 94-96 vol.%, Each determined according to DIN 52102. It was found within the scope of the invention that the use of lightweight aggregate with closed pores, especially expanded glass, is particularly advantageous. Unlike the other lightweight aggregates, expanded glass due to its spherical structure also has a not fully open pore structure in the interior. However, with microcracks, a large part of the total pore volume gradually fills with delay. Thus, the expanded glass acts as a fluid accumulation that slowly absorbs and releases water. This is especially important when the mortar plate 1 is to be adapted to a very porous wall which tends to suck the water away from the mortar plate 1 (eg in calcareous sandstones). Thereby, the curing process of the cement may be disturbed by a too low v / c ratio. By the targeted use of lightweight aggregate with closed pores, especially expanded glass, absorption and thus strength can be controlled. In addition, the expanded glass holds relatively well on water also under pressure, thus comprising a pressure-stable water absorption. Rather, light aggregates with open pores absorb the water rather spongy and release it under pressure. Because of this, a certain amount of more water is released from the lightweight open pore assembly at the pressure of the plastering wall. Among other reasons, the proper composition of the lightweight assembly is very important. In particular, it depends on the proper composition of the lightweight assembly with open and closed pores. Preferably, therefore, the dry mortar layers 3,4 each contain 1 to 20% by weight, preferably 5 to 15% by weight, lightweight closed pore aggregate, preferably expanded glass. The rest of the lightweight unit consists of a unit with open pores.

The dry space weight p0 for the dry mortar plate 1 is preferably 0.8 to 1.2 kg / dm3, preferably 0.9 to 1.1 kg / dm3. For the determination of p0, the dry mortar plate 1 was dried at 40 ° C until constant mass. The low dry space weight and the high porosity can also be adjusted by the proportion of the light aggregate with open and closed pores.

According to another independent aspect of the invention, the dry mortar plate 1 has at least one of the layer tops 8 or plate tops 13a, b, preferably several, gutter-like or trough-like or bowl-like recesses 15 to receive a defined amount of water upon irrigation of the dry mortar plate 1 of the invention. Trough-like recesses 15 serve as closed water reservoirs or self-sealed containers for storing a defined amount of water, which will be discussed in more detail below. Trough-like recesses 15 each have a trough bottom 16 as well as two opposite trough length walls or trough length walls 17 and two opposite trough walls 18. The trough wall 18 extends perpendicularly to the trough side walls 16 and parallel to the plate length direction 1a.

The trough side wall 17 thus extends parallel to plate cross-section 1b. Thus, the trough side wall 17 extends parallel to the plate end edge 12. The trough bottom 16 is perpendicular to the plate thickness direction 1c. Trough-like recesses 15 are also arranged adjacent to each other longitudinally 1a. In particular, the dry mortar plate 1 1 to 15, preferably 5 to 10, has mutually adjacent trough-like recesses 15. Between each pair of mutually adjacent trough-like recesses 15, each has an inner web wall or intermediate web wall 19. Furthermore, each has an outer continuous continuous wall wall or edge web wall. 20, which limits and surrounds the trough-like recesses 15 and extends up to both plate end edges 12 and plate side edges 11.

Due to the trough-like recesses 15 and the web walls 19, 20, the top surface 13a of the plate is provided with ribs. This improves the stability, especially the stiffness, of the dry mortar plate 1 surprisingly. The circumferential edge web walls 20 also cause the dry mortar plate 1 to no longer crumble at the edges. The edge web wall 20 represents an accumulation of material and causes, in the watered state, that the edge areas of the bricks are provided with sufficient mortar. This increases the strength. In addition, the plastic-made, irrigated edge web walls 20 support a balancing effect. As a result, the joint is very uniform. The edge web wall 20 preferably has a width b (measured from each plate edge 11 or 12) of 2 to 50 mm, preferably 5 to 35 mm. The depth of the trough depends in particular on the degree of exposure (v / c ratio DIN 1045) and binder. The depth of the trough-like recesses 15, relative to a thickness d of the mortar plate 1, is preferably 20 to 80%, especially 30 to 60%.

Thus, of course, it is within the scope of the invention that the cross-sectional U-shaped trough-like recesses 15 (Fig. 1) are not rectangular, but are instead rounded. The trough-like recesses 15 may also have other than rectangular floor plans.

The thickness d, i.e. the extent in the plate thickness direction 1c of the dry mortar plate 1 according to the invention is preferably 1.5 to 100 mm, preferably 2 to 40 mm, depending on whether the dry mortar plate 1 is to be used to make a thin bed of mortar layer or a thick bed of mortar layer.

The following describes in detail the process for making the dry mortar plate 1 according to the invention: The apparatus 21 used in the method according to the invention has a first mortar applicator 22, a carrier strip applicator 23, a second mortar applicator 24, preferably a preheater, a press device. 25, preferably a shutter device, a cooling section or cooling device 26, preferably a control device, and a packaging device 27.

[0035] By means of the first mortar applicator 22, a first dry mix 28 consisting of the dry mortar mixture and the adhesive on granular or powder form is introduced for the first dry mortar layer 3 with the profiled plate surface 13a in the cassette mold 29, in particular sprinkled. For this purpose, the first mortar applicator 22 has a first reservoir 30 for the first dry mix 28, and a suitable applicator. For the application means it is e.g. whether a rotary valve 31 or a flap. Preferably, the first mortar applicator 22 has, in addition to a tear tape or the like, to smooth the surface of the sprayed first dry mix 28. The first dry mix 28 is applied particularly to the bottom of the mold 32 of the cassette mold 29. The bottom of the mold 32 is preferably profiled and has a negative shape of the profiled plate top 13a or layer top 8 with the trough-like recesses 15 to be produced. The cassette mold 29 and also the first reservoir 30 may also be heated.

As already explained, the invention provides that the dry mortar layers 3,4 contain a high proportion of light aggregate with open and closed pores. This is firstly ensured by dry mortar layer 3 by a suitable composition of the first dry mixture 28. In particular, the first dry mixture 28 has a proportion of 20 to 60 vol.%, Preferably 30 to 50 vol.%, Light aggregate with open and closed. pores, based on the total dry weight of the dry mortar mixture. The proportion of light aggregate with closed pores, especially expanded glass, is thereby preferably 2 to 30 vol.%, Preferably 10 to 25 vol.%.

Preferred compositions of the first dry blend 28 are also listed below based on dry matter (the individual components yield 100% by volume):

Thus, within the scope of the invention, it was found that the sieve curve is essential for the dry mortar mixture, especially the lightweight, closed and open pore aggregate, to create a defined pore volume. In particular, the light aggregate with open and closed pores of the first dry mix 28 has the following particle size distribution, determined on the basis of the material determined by sieving (the individual components add up to 100% by weight):

Depending on the thickness of the dry mortar layers 3.4, a coarser grain size may also be used. The preferred particle size distribution is as follows (the individual components again add up to 100% by weight):

In addition, the first dry mix 28 preferably comprises the following sieve curve (sieve residue is indicated):

or for coarser grains:

The carrier strip application device 23 is disposed over the cassette mold 29 and serves to place the carrier strip 2 on the first dry, looser mixture 28. The carrier strip application device 23 preferably comprises a supply roller 33 with endless carrier strip extension device 33, an extender strip device 33, a smoothing device 33 and a cutting device 35 for cutting the carrier strip 2 from the smoothed endless carrier strip material 33 and means for applying the cut carrier strip 2 to the first dry mix 28.

At the smoothing device 34, it is e.g. about two heated plates or rolls. In the leveling device 34, the endless carrier strip material 33 is applied after unwinding from the supply roller with pressure and temperature. It is thus smoothed. Without smoothing, it may happen that the cut support strip 2 curls strongly when wound up on the supply roll. This can cause problems. In particular, it is difficult to place cut-off support strip 2 at a defined location on the first dry mix 28. This may affect the stability of the dry mortar plate 1 By smoothing, the support strip 2 comprises a uniform and defined reproducible shape. Of course, it is also within the scope of the invention to level the carrier strip 2 after cutting.

In the cutting device 35, for example, about a swivel blade or two rolling wheels.

[0044] By means of the second mortar application device 24, the second dry mixture 36 comprising the dry mortar mixture and the adhesive in granular or powder form is applied to the second dry mortar layer 4 on the carrier strip 2, in particular the sprinkler. For this purpose, the second mortar applicator 22 comprises a second container 37 for the second dry mixture 36 and a suitable applicator. In the application means again it is e.g. a rotary valve 38 or a flap. Preferably, the second mortar applicator 24 further comprises a removable strip 40 or the like to smooth the surface of the sprayed second dry mixture 36. Thus, a uniform distribution of material in the cassette mold 29 is ensured.

The second dry mixture 36 is compositionally preferably identical to the first dry mixture 28. In this case, the second dry mixture 36 is also coated with the same mortar applicator 22 as the first dry mixture 28.

The pre-existing preheater is used to preheat the dry blends 28.36. In particular, the dry mixtures 28.36 are brought to the same initial temperature.

By means of the pressing device 25, the two dry mixtures 28,36 and the inserted carrier strip 2 are simultaneously subjected to pressure and temperature. Preferably, several cassettes 29 are exposed simultaneously. For this purpose, the pressing device 25 comprises at least one, in particular several, heated mold covers 39 corresponding to or corresponding to the cassette mold 29. The mold cover 39 is arranged on top of each of the cassette molds 29, so that in each case a closed press mold is formed. In the mold, the dry mixtures 28,36 are compressed and at the same time the adhesive melts. The liquid adhesive now distributes in the blends 28.36, joins with the constituents of the dry blends, and thus partially penetrates the light aggregate particles 14. The two dry mortar layers 3,4 are formed. The distribution of the adhesive is thereby substantially increased by the simultaneous application of pressure. In addition, both the solid, non-meltable components of the dry mortar mixtures and the adhesive are pushed through the holes 7 in the carrier strip 2 and the two dry mortar layers 3,4 are connected to each other and to the carrier strip 2.

It was found within the scope of the invention that the applied pressure should not be too high. Otherwise, the lightweight aggregate particles would be completely destroyed during compression. This would impair the water permeability of the finished dry mortar plate 1 and lead to insufficient wetting of the dry mortar mixture during irrigation. On the other hand, too low pressure leads to insufficient cohesion in the dry mortar plate. Preferably, the applied pressure is from 0.1 to 20 bar or from 0.2 to 20, preferably 2 to 6 bar. More preferred pressure at 0.1 to 3 bar is or 0.2 to 3 bar, especially at 0.5 to 2.5 bar. Furthermore, it has been found within the scope of the invention that the temperature has a decisive influence on the quality of the dry mortar board 1. At too low temperatures, the adhesive is not sufficiently activated. The dry mortar plate does not have sufficient cohesion. At too high temperatures, the adhesive is gaseous and escapes, which also leads to insufficient cohesion. Thus, preferably, the temperature is from 30 to 250 ° C, preferably from 100 to 170 ° C. The pressing process thus preferably takes 10 to 500 seconds, preferably 10 to 200 seconds.

Furthermore, within the scope of the invention, it has been found that cassette mold 29 and mold cover 39 should comprise a non-adhesive coating to minimize adhesion of the cassette mold or mold cover 39 to the dry mortar plate 1 and to provide a residual free removal from the mold . Also, draft angles are important. Preferably, the non-adhesive coating consists of a temperature-resistant plastic material, in particular a rubber-like resilient plastic material, preferably of silicone or polyurethane (PU) or teflon (PTFE). The non-adhesive coating may also consist of an oxide material e.g. SiO2 or TiO2 or a metallic material such as chromium or aluminum, etc. As an alternative to non-adhesive coating, the cartridge mold 29 and mold cover 39 consist of a metallic material, e.g. beam, aluminum or titanium, wherein the abrasive surface is polished or abrasive, and preferably provided with an abrasive, in particular an oil, grease, tallow and / or carbon black. In each case, the release agent is applied to the empty cassette mold 29 and the mold cover 39 before closing.

After pressing, the mold is reopened, the mold cover 39 being taken out of the cassette mold 29. Since the cassette mold 29 comprises the negative mold of the trough-like recesses 15, the trough-like recesses 15 of the pressing process are incorporated into the dry mortar plate 1, in particular pressed.

The dry mortar plates 1 are now removed from the mold and then cooled in the cooling device 26. The dry mortar plates 1 cool so that the adhesive hardens and the solidified, hardened solid adhesive matrix is formed.

[0052] By means of the existing control unit, for example, the weight and / or the surface and / or absence of fracture are checked. And by means of the packaging device 27, the dry mortar plates 1 are still preferably packed in a cardboard tray and wrapped in a film 41 or packed in a thermopause. Preferably, the film 41 or thermopause is subsequently evacuated so that the dry mortar plate 1 packages are vacuum packed. Then the packages are stacked on each other.

The process according to the invention can e.g. It is realized that the individual units 22, 23, 24, especially during loading and unloading, move relative to the cassette mold 29 and cassette mold 29 are at rest. However, this can also be reversed or take place in an overlaid relative motion.

As already explained, dry mortar sheets 1 according to the invention are preferably used to produce a fresh mortar layer 45 for covering thin layer plaster of hollow brick 46 or other walls. In addition, the individual dry mortar plates 1 are placed on a first, lower row of bricks 47. The first hollow brick row 47 consists in known manner of hollow bricks 46, which in construction each with a butt joint 48 abut each other. On the first row of bricks 47, the dry mortar plates 1 are positioned and thereby also preferably positioned with their plate end 12 to edge, to form a butt joint 49 to each other. Furthermore, the dry mortar plates 1 are positioned so that the profiled plate surface 13a faces upwards. In addition, the dry mortar plates 1 are preferably positioned such that the butt joints 49 are added between the dry mortar plates 1 to the butt joints 48 between the hollow bricks 46 in the first row of bricks 47 in the vertical direction.

After placement of the dry mortar plates 1, these are watered e.g. with a watering can. Thereby the trough-like recesses 15 are filled with water. Excess water flows over the trough-like recesses 15 and off. This ensures that exactly the right amount of water is available to irrigate the dry mortar plates 1. The water seeps into the dry mortar plates 1, flows through the water-permeable carrier strip 2, humidifies the individual constituents of the dry mortar mixture and gradually dissolves the adhesive so that the dry mortar leaves 1 each forming individual reinforced fresh mortar layers. The individual, adjacent layers of fresh mortar are thereby directly adjacent to each other and thereby interlocking, so that a continuous fresh mortar layer 45 is formed (Fig. 5), thereby ensuring the high proportion of light aggregate according to the invention despite the compression that the water flows rapidly through the entire dry mortar plate 1 and all components are sufficiently moistened.

After watering, a second row of tiles 50 is placed on fresh mortar layer 45 and preferably fixed with a pair of hammer strokes. Thereby, the individual cavity bricks 46 are set against one another again to form a butt joint 51. The cavity bricks 46 are preferably arranged such that the butt joints 49 between the dry mortar plates 1 (in Fig. 5 still indicated by dashed lines) align vertically with the butt joints 51 between the hollow brackets 46 in the second row of bricks 50. The length of the dry mortar sheets 1 thus corresponds to the length of the cavity brick 46. By placing and pressing the cavity brick 46 on or in the fresh mortar layer 45, the individual adjacent adjacent mortar layers can be further mixed.

According to a further embodiment of the invention (Fig. 6), the dry mortar plates 1 are longer than the hollow bricks 46. Thus, the bumps 48,49,51 are offset from one another. This increases the overall stability of the masonry.

As already explained above, surprisingly within the scope of the invention it has been found that it is possible to clearly improve the strength and abrasion resistance of a dry mortar board according to the invention by a very high proportion of open and closed pores. This was not to be expected. Because lightweight aggregate particles with open or closed pores in the lightweight aggregate are known to have very small particle pressure resistance. Thus, it would actually be expected with higher wear and deterioration strength properties. This could be because the liquid, molten binder, especially due to the same applied pressure, penetrates into the pores of the lightweight aggregate particles and, after cooling, is mechanically drilled into them. Thereby, the cohesiveness between the individual constituents of the dry mortar mixture is greatly improved, which leads to the good strength properties and the poor wear of the dry mortar plate according to the invention.

In addition, the strength properties of the cured mortar layer made from the dry mortar sheets are surprisingly enhanced by the large proportion of light aggregate. Because, due to the pore cavity produced by the assembly, the water can flow freely through the dry mortar plate and wetting all the components of the dry mortar plate sufficiently and uniformly. Thus, much less water is required than in the known mortar bands. As these include a more dense structure. This can only be ensured with such a large amount of water that all components are moistened. In a dry mortar plate according to the invention, the w / c ratio, which in turn is determined by the trough-like recesses, is considerably lower. In addition, the water is evenly distributed in the fresh mortar. All of this leads to improved strength of the subsequent dry mortar layer, and to less shrinkage during hydration. At the edge areas produced by the trough-like recesses, the crumble is also reduced. In addition, it is also possible for unskilled labor to use the system, since the measured amount of water is predetermined.

Further advantages of dry mortar boards according to the invention are freedom from dust when used on the site and environmental protection through efficient energy and resource consumption. Another advantage is also the easy handling, as a suitable format can be made for each wall. Thereby the cutting is less.

As already explained, the process of the invention concomitantly applies the pressure and temperature of the dry mixtures to the fact that the adhesive penetrates the open pores of the light aggregate particles. The pressure should not be too high so that the lightweight aggregate particles are not destroyed.

Within the scope of the invention it is also possible to use dry mortar plates 1 according to the invention to fix tiles or similar plates or to fix insulating plates or similar facade elements or to produce a wall without additional wall of construction.

Furthermore, it is within the scope of the invention to produce the dry mortar plate as a multi-layer dry mortar plate having more than two dry mortar layers or as a single dry mortar plate with only one dry mortar layer. In the latter case, no other dry mixture is applied to the carrier strip and the other mortar-applying device is omitted. In a multilayer dry mortar plate, the corresponding number of first and second dry mixtures is applied, where these mixtures may be different. The dry mortar plate may also have multiple support strips. Production takes place by analogy, the respective number of dry mixtures and carrier strips being alternately introduced into the cassette form.

In addition, the carrier strip as reinforcement may be omitted. The dry mortar plate 1 is then constructed as e.g. single layer and consists of a single dry mortar layer 3 (Fig. 7). Preferably, in this case, the dry mortar layer 3 comprises a reinforcement in the form of individual fibers distributed in the dry mortar layer 3. do not apply a carrier strip to the first dry mixture. Likewise, the dry mortar plate may be, without a carrier strip, having multiple layers consisting of several superimposed, dry-mortar layers interconnected by the adhesive (not shown). The required dry mixtures are then sprinkled into the cassette mold.

Claims (15)

A dry mortar plate (1) comprising at least one dry mortar layer (3), comprising a dry mortar layer (3) solidified by a water-soluble adhesive, wherein the dry mortar mixture consists of a mineral, in particular hydraulic, binder. granules and optionally at least one additive and / or at least one additive, characterized in that the dry mortar mixture comprises, based on the dry matter of the dry mortar mixture, 5 to 35% by weight, preferably 10 to 25% by weight, light granulate comprising light granulate particles (14 ) with open pores and closed pores. Dry mortar plate (1) according to claim 1, characterized in that the dry mortar layer (3) comprises a fixed adhesive matrix of the water-soluble adhesive which binds the components of the dry mortar mixture to each other. Dry mortar plate (1) according to any one of the preceding claims, characterized in that the lightweight or closed pore lightweight aggregate is perlite or vermiculite or expanded glass or hydrosilicate or expanded clay or mixtures of the aforementioned lightweight aggregates. Dry mortar plate (1) according to any one of the preceding claims, characterized in that the proportion of closed pore aggregates, in particular expanded glass, based on the dry matter of the dry mortar mixture is preferably 1 to 20% by weight. %. Dry mortar plate (1) according to any one of the preceding claims, characterized in that the light aggregate particles with open pores (14) have a particle compression strength of 0.01 to 2 N / mm 2, preferably 0.01 to 1 N / mm2 and / or the light aggregate particles with closed pores (14) have a particle compression strength of 2 to 7 N / mm2. Dry mortar plate (1) according to any one of the preceding claims, characterized in that the adhesive has penetrated into the lightweight aggregate particles (14). Dry mortar plate (1) according to any of the preceding claims, characterized in that the dry mortar plate (1) has a support strip (2) which is coated on one side with at least one dry mortar layer (3) according to any of the the preceding claim, wherein the support strip (2) is preferably covered on both sides with at least one dry mortar layer (3,4) according to any of the preceding claims, wherein the dry mortar layer (3,4) is preferably arranged so that it aligns with another in the plate height direction ( 1c). Dry mortar plate (1) according to claim 7, characterized in that the solid adhesive matrix in each case binds the components of the dry mortar mixture (s) to each other and to the carrier strip (2). Dry mortar plate (1), in particular according to one of the preceding claims, comprising at least one dry mortar layer (3), wherein the dry mortar layer (3) comprises a dry mortar mixture solidified by a water-soluble adhesive, wherein the dry mortar mixture consists of a mineral acid, in particular hydraulic , binder, aggregate and optionally at least one additive and / or at least one additive, wherein the dry mortar plate (1) comprises a layer on the upper side (8) forming a plate top (13a) of the dry mortar plate (1), characterized in that: at least one trough-like recess (15) for holding water is present in the upper side (13a) of the plate, where preferably several trough-like recesses (15) are present adjacent to each other in the plate length direction (1a), wherein an intermediate wall of tissue (19) is present between every two trough-like recesses (15) and a peripheral wall of tissue (20) is present which surrounds all trough-like recesses (15). A process for preparing a dry mortar plate (1) according to any one of the preceding claims, with the following process steps: a) introducing at least one dry mixture (28) consisting of the dry mortar mixture and the adhesive into a cassette mold (29), is open at the top, b) preferably placing the carrier strip (2) on the top of the dry blends (28), c) preferably applying at least one additional dry mixture (36) consisting of the dry mortar mixture and adhesive to the carrier strip (2), d) optionally repeating steps b) and c) at least once; e) simultaneously exposing the mixture (s) (28.36) to pressure and temperature so that the adhesive melts and enters the lightweight aggregate particles (14), f) cooling and allow the adhesive to harden. A method of preparing a dry mortar plate (1) according to claim 10, with the following process steps: a) introducing a first dry mixture (28) into the cassette mold (29) open at the top, wherein the first dry mixture (28) comprises the dry mortar mixture and the adhesive to produce the first dry mortar layer (3), b) placing the carrier strip (2) on the first dry mixture (28), c) preferably applying a second dry mixture (36) to the carrier strip (2), wherein the second dry mixture (36) comprises the dry mortar mixture and the adhesive for preparing the second dry mortar layer (4), d) simultaneously exposing the mixture (s) (28, 36) and optionally the carrier strip (2) to pressure and temperature so that the adhesive melts and penetrates in the lightweight aggregate particles (14), e) cooling and allowing the adhesive to harden. Process according to claim 10 or 11, characterized in that a dry mixture (28,36) comprising in each case 30-60 vol.%, Preferably 35-50 vol.% Light aggregate with open pores and closed pores, preferably a dry mixture (28,36) in each case having the following composition: Process according to one of claims 10 to 12, characterized in that the light aggregate with open pores and closed pores of a dry mixture (28,36) in each case comprises the following particle size distribution (the individual components give 100% by weight): or Process according to one of claims 10 to 13, characterized in that in each case a dry mixture (28,36) comprises the following sieve curve (screening residue is indicated): or A method according to any one of claims 10 to 14, carried out in an apparatus comprising: a) at least one top mold cassette mold (29), b) a first mortar applicator (22) for introducing first dry blend (28) (c) preferably a carrier strip applying device (23) for placing the carrier strip (2) on the first dry mixture (28), d) preferably a second mortar application device (24) for applying it. a second dry mix (36) for the carrier strip (2) or the first dry mix (28), e) a pressing device (25) for simultaneously subjecting the dry mixture (s) (28,36) and optionally the carrier strip (2) for pressure and temperature so that the adhesive melts and enters the lightweight aggregate particles (14), f) a cooling section (26) for cooling, and allows the adhesive to cure, preferably the pressure device (25) comprises a mold cover (39) corresponding to the cassette mold (2). 9), wherein the cassette mold (29) and mold cover (39) in each case have an anti-adhesive coating, in particular comprising elastic plastics material, preferably consisting of silicone or polyurethane or teflon.